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Six sigma is one of the perfect problem-solving methodologies. This process is applied in most of organizations and the projects they work in. So using this process, the organizations can actually understand the root cause of the problem and also the costs associated to fix the same.
So using this six sigma process, the organization will be able to identify the root cause of the problem and put in necessary fixes, and also try to reduce the cost associated with the same by taking precautions that the same mistake or error doesn’t happen again.
It is measured based on the DPMO factor, i.e. Defect per Million Opportunities.
Six sigma is nothing but a process improvement methodology where the root cause of the errors is identified and ultimately helps in improving the overall process. So when it comes to the Six Sigma level, one has to check with the DPMO score.
If the accuracy of the process gets to a level where it has only 3.4 defects per million opportunities. Below, is the list of defects per million that are catered towards a single level:
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The following are the different kinds of variations that are used in the six sigma process:
Mean: This measurement is actually considered only for a particular application and the values are calculated. So within this process, the variations are actually measured and compared using average techniques of mathematics.
Median: This process is initiated by identifying the highest and the lowest values and then divide the value by 2. Within this process, the variations are actually measured and compared by taking the midpoint of the data set range.
Range: As the name implies it actually takes into consideration of highest rate and lowest values for a specific date range.
Mode: Mode is nothing but the most occurred values in a given data set range.
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So within an organization, the following roles or designated individuals will be a part of the six sigma implementation part, they are as follows:
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Well, these are the individuals who will be responsible for driving initiatives to make sure their product quality and processes are optimized to a profitable level where the entire team is being productive with fewer operations costs incurred.
So most of the time, the executive leaders will be the CEO or Board of director members, etc. The main motto of these individuals is to make sure that they deliver a quality product to the customers and make sure they are satisfied.
So champions are more likely senior managers that manage micro teams based on individual projects they deal with.
So most of the time they promote good aspects of implementing Six Sigma processes and also do involve coaching and mentoring if needed.
The main role of the Master black belt holder of the six sigma process is vital for an organization because most organizations don’t start with a concrete six sigma process.
So building up the practice and making sure that they are in line with the standards is very important. So the core process is initiated and mentored if necessary to the users who are part of the six sigma process implementation team.
They are two six sigma sub methodologies that are available for the teams to focus on, they are:
Well, DMAIC stands for Define, Measure, Analyze, Improve, and Control. Within this process, it is an improvement system for all the existing processes where they identify whether there needs to be any process improvement and look for it on regular basis to achieve the ultimate process efficiency.
So basically, this process to execute has 5 different phases where the entire functional flow or the process is evaluated on different parameters which eventually results in the optimized process flow for a better and concrete outcome.
So the six sigma process was developed by Motorola to make sure that their products are measured in terms of the highest quality and the year it was invented in 1986.
They are many third-party tools that can be integrated with the Six Sigma process to achieve process efficiency. The methods that six sigma follows are:
The difference between load testing and performance testing is as follows:
Well, a lean six sigma is nothing but a methodology that involves the entire team effort to bring them in the change in terms of performance improvement by identifying the waste and the variance reduction.
So in conjunction with the lean six sigma process and eliminates 8 different kinds of wastes, they are as follows:
Well, these are few areas where the process flow can be improvised and get maximum benefits by optimizing the entire process flow.
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The benefits of the six sigma process are as follows:
The main difference between lean and six sigma is that lean methodology focuses on waste reduction within a process flow. Whereas, six sigma process focuses mainly on variation analysis and variance reduction.
The popular myths or misunderstanding about six sigma process is as follows:
The three key elements for six sigma process improvement are as follows:
Customers: They are the sole owners of the entire process outcome so we need to define all possible metrics so that the attributes like on-time delivery, customer satisfaction, pricing, service, and transaction processing activities should be crystal clear. It is very important and one has to make sure that all are dealt with.
Process: This is the critical aspect of the Six Sigma process implementation. For any customer, they would look for a quality product. So as six sigma process implementers we need to take due care to understand this process from the customer’s perspective.
Employees: Finally the last thing to have a successful six sigma process implementation is to include all the employees of the organization and provide them an opportunity to grow their skill set.
The top-down approach is one of the processes within Six Sigma implementation. So usually this type of approach is in line with the business strategy and the customer needs.
But it has one of the major disadvantages is that the scope is very broad and at the same time it is difficult to be executed in a specified amount of time.
As per the industry standards, the six sigma projects are executed and completed in the time span of 3 to 6 months.
SIPOC stands for Suppliers Input Process Output Customers.
A process can be defined as a series of consecutive steps and activities that are executed in a timely manner to get a definite output.
The SIPOC process map is very important for identifying the following elements:
FEMA stands for the Final segment of the Measure Phase.
So basically it promotes the cause of preventing defects before even they occur. So in a sense being proactive and making sure that are no known defects within the process.
Within the FEMA process they generally include the possible defects and rate them accordingly in three different ways, they are:
If the defect severity is considered to be low then the user does not have to spend more time in terms of validating the process.
The three steps for Root cause analysis is:
Open step: This is the initial step where all the team members are gathered together and do a brainstorming session on all possible scenarios.
Narrow step: During this phase, all the possible explanations and scenarios are narrowed down to an extent considering our current sigma performance.
close step: During this phase, the project team will validate all the narrowed-down list of explanations for the current sigma performance.
DFSS stands for Define for Six Sigma.
This process is actually involved in designing or redesigning the service or a product from scratch. One of the cases where the project is following DMAIC methodology goes into the DFSS project because of the designing related tasks.
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A Pareto chart is used to display the data and the tool is based on the underlying concept of the Pareto principle. It is often called as 80/20 rule.
Using this rule will help the team to focus on specific tasks and issues which might have a greater impact if they are not looked into at the initial stages.
Well, the cost of six sigma implementation is estimated by the organization in different ways and a few of the popular ones are listed below:
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A data collection plan is nothing but a plan which is used to collect the necessary data. So within this plan, the following aspects are covered.
So the main reason to collect data is to understand the current process and portray possible improvement suggestions. The data can be collected from three different primary sources they are as follows:
Input: input is nothing but where the data is generated.
Process: the process is nothing but the execution steps where the factors like efficiency, time requirements, cost, defects are taken into consideration for process improvements.
Output: it is a straight measurement of efficiency.
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